Multi-axis final drive assembly

ABSTRACT

A final drive assembly for a vehicle drive axle having first and second axle-shafts that are configured to rotate about a common first axis. The final drive assembly includes a first gear-set configured to be operatively connected to the first axle-shaft. The final drive assembly also includes a second gear-set configured to be operatively connected to the second axle-shaft. The final drive assembly additionally includes an electric motor configured to provide an electric motor torque input to each of the first and second gear-sets and arranged on a second axis that is parallel to the first axis.

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application is a divisional application of U.S. patent applicationSer. No. 15/334,333 filed on Oct. 26, 2016, the entire contents of whichare hereby incorporated by reference.

INTRODUCTION

The disclosure relates to a multiple-axis final drive assembly thatemploys an electric motor to drive a pair of opposite side wheels in avehicle.

Modern motor vehicles are typically configured as either two- orall-wheel-drive. Either type of a vehicle may employ a conventionalpowertrain, where a single engine is used to propel the vehicle, anelectric powertrain, where an electric motor is used to propel thevehicle, or a hybrid powertrain, where two or more distinct powersources, such as an internal combustion engine and an electric motor,are used to accomplish the same task.

An all-wheel-drive hybrid vehicle may be configured as an axle-splitvehicle. In such a vehicle, independent power-sources, such as aninternal combustion engine and an electric motor, are set up toindependently power individual vehicle axles that are operativelyconnected to the respective power-sources, thus generating on-demandall-wheel-drive propulsion. In such an axle-split hybrid vehicleemploying an engine and an electric motor, the electric motor may becapable of propelling the vehicle via the respective axle while theengine is shut off.

Each powered axle typically includes a final drive assembly with adifferential that allows opposite side, i.e., left and right side,driven wheels to rotate at different speeds when the vehicle negotiatesa turn. Specifically, the differential permits the driven wheel that istraveling around the outside of the turning curve to roll farther andfaster than the driven wheel traveling around the inside of the turningcurve, while approximately equal torque is applied to each of the drivenwheels. An increase in the speed of one driven wheel is balanced by adecrease in the speed of the other driven wheel, while the average speedof the two driven wheels equals the input rotational speed of the driveshaft connecting the power-source to the differential.

SUMMARY

A final drive assembly for a vehicle drive axle has first and secondaxle-shafts that are configured to rotate about a common first axis. Thefinal drive assembly includes a first gear-set configured to beoperatively connected to the first axle-shaft. The final drive assemblyalso includes a second gear-set configured to be operatively connectedto the second axle-shaft. The final drive assembly additionally includesan electric motor configured to provide an electric motor torque inputto each of the first and second gear-sets and arranged on a second axisthat is parallel to the first axis.

The final drive assembly may also include a first differential shaftoperatively connected to the first gear-set and a second differentialshaft operatively connected to the second gear-set. The final driveassembly may additionally include a third, differential gear-setoperatively connecting the electric motor to the first and seconddifferential shafts.

In the embodiment of the final drive assembly having the differentialgear-set, each of the first and second gear-sets may be configured as aparallel-shaft transfer or reduction gear-set. The first parallel-shafttransfer gear-set may be operatively connected to the first differentialshaft, while the second parallel-shaft transfer gear-set may beoperatively connected to the second differential shaft. Each of thefirst and second parallel-shaft transfer gear-sets may include arespective first and second intermediate gears arranged to rotate abouta third axis that is parallel to each of the first and second axes.Alternatively, each of the first and second gear-sets may be configuredas a planetary or epicyclic gear-set configured to rotate about thefirst axis and having first, second, and third members. The firstplanetary gear-set may be operatively connected to the firstdifferential shaft and the second planetary gear-set may be operativelyconnected to the second differential shaft.

Each of the first and second gear-sets may also be configured as aplanetary gear-set that rotate about the first axis in the final driveassembly configured without the above differential gear-set. The finaldrive assembly may also include a final drive housing. In such a case,the electric motor may include a stator fixed to the final drivehousing, a rotor, and an outer shaft fixed to the rotor for rotationtherewith. The outer shaft may be in mesh with each of the third memberof the first planetary gear-set and the third member of the secondplanetary gear-set.

The final drive assembly may additionally include an inner shaftextending through the outer shaft, in mesh with the first member of thefirst planetary gear-set, and operatively connected to the first memberof the second planetary gear-set.

The inner shaft may be operatively connected to the first member of thesecond planetary gear-set via an idler gear. In such a case, the idlergear is configured to reverse a direction of rotation of the firstmember of the second planetary gear-set relative to a direction ofrotation of the inner shaft.

The final drive assembly may additionally include an actuator configuredto selectively disconnect the inner shaft from one of the first andsecond planetary gear-sets.

The first axle-shaft may be continuously connected to the second memberof the first planetary gear-set and the second axle-shaft may becontinuously connected to the second member of the second planetarygear-set.

In each of the first and second gear-sets, the first member may be aring gear, the second member may be a planetary carrier supporting aplurality of pinion gears in mesh with the first and second members,while the third member may be a sun gear.

A vehicle drive axle for being mounted in a motor vehicle and employingsuch a final drive assembly is also disclosed.

The above features and advantages, and other features and advantages ofthe present disclosure, will be readily apparent from the followingdetailed description of the embodiment(s) and best mode(s) for carryingout the described disclosure when taken in connection with theaccompanying drawings and appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic illustration of a vehicle employing a hybridelectric powertrain that includes an internal combustion engineoperatively connected to a first axle and a second axle employing afinal drive assembly incorporating an electric motor, according to thedisclosure.

FIG. 2 is a schematic close-up cross-sectional plan view one embodimentof the final drive assembly shown in FIG. 1.

FIG. 3 is a schematic close-up cross-sectional plan view anotherembodiment of the final drive assembly shown in FIG. 1.

FIG. 4 is a schematic close-up cross-sectional plan view yet anotherembodiment of the final drive assembly shown in FIG. 1.

DETAILED DESCRIPTION

Referring to the drawings in which like elements are identified withidentical numerals throughout, FIG. 1 illustrates a vehicle 10 that usesan electric motor, to be discussed in greater detail below, to drive apair of opposite, a left and a right, side wheels. As shown, the vehicle10 is hybrid vehicle having independent first and second power-sourcesthat are operatively connected to respective sets of driven wheels inorder to provide on-demand all-wheel-drive propulsion. The vehicle 10may include, but not be limited to, a commercial vehicle, industrialvehicle, passenger vehicle, train or the like. As shown, the vehicle 10is generally arranged along a longitudinal vehicle axis X. The vehicle10 includes a first power-source shown as an internal combustion engine12 configured to drive the vehicle via a first set of wheels, whichincludes a first or left-side wheel 14-1 and a second or right-sidewheel 14-2, for transmitting engine output or drive torque T1 to a roadsurface 13 through a transmission assembly 16 and a first axle 18.

The vehicle 10 additionally includes a second axle 20. The second axle20 is operatively independent from the engine 12 and the transmission16. The second axle 20 includes an electric motor-generator 22 that isconfigured to drive the vehicle 10 via a second set of wheels, whichincludes a first or left-side road wheel 24-1 and a second or right-sideroad wheel 24-2. The electric motor-generator 22 receives its electricalenergy from an energy storage device 26. As understood by those skilledin the art, the motor-generator 22 includes a stator 22-1 and a rotor22-2 configured to impart a motor-generator output or drive torque T2.According to the present disclosure, the electric motor-generator 22 isconfigured to drive the vehicle 10 via the drive torque T2 independentlyfrom the engine 12 and provides the vehicle 10 with an on-demandelectric axle drive. The vehicle 10 may be driven solely via theelectric motor-generator 22, i.e., in a purely electric vehicle or “EV”mode. On the other hand, when both first and second axles 18, 20 aredriven by the respective engine 12 and the electric motor-generator 22,the vehicle 10 is endowed with all-wheel-drive.

The second axle 20 includes a first axle-shaft 28-1 operativelyconnected to the left-side road wheel 24-1 and a second axle-shaft 28-2operatively connected to the left-side road wheel 24-1. Each of thefirst and second axle-shafts 28-1, 28-2 is configured to rotate about acommon first axis Y1. As may be seen, the first axis Y1 is arrangedgenerally perpendicular to the longitudinal vehicle axis X. The secondaxle 20 also includes a final drive assembly 30 configured to transmitthe drive torque T2 to the first and second axle-shafts 28-1, 28-2. Thefinal drive assembly 30 also includes a first gear-set 32-1 operativelyconnected to the first axle-shaft 28-1. The final drive assembly 30additionally includes a second gear-set 32-2 operatively connected tothe second axle-shaft 28-2. The motor-generator 22, being part of thefinal drive assembly 30 is configured to provide the drive torque T2input to each of the first and second gear-sets 32-1, 32-2. Themotor-generator 22 is arranged on a second axis Y2 that is parallel tothe first axis Y1.

FIG. 2 illustrates a final drive assembly 130, which is a specificembodiment of the final drive assembly 30 shown in FIG. 1. The finaldrive assembly 130 may include a first differential shaft 34-1operatively connected to the first gear-set 132-1 and a seconddifferential shaft 34-2 operatively connected to the second gear-set132-2. In the embodiment of FIG. 2, the final drive assembly 130 mayalso include a third gear-set 36 configured as a differential. Thedifferential gear-set 36 operatively connects the electric motor 22 tothe first and second differential shafts 34-1, 34-2. Furthermore, asshown in the final drive assembly 130, each of the first and secondgear-sets 132-1, 132-2 may be configured as a parallel-shaft transfer orreduction gear-set. The first parallel-shaft transfer gear-set 132-1 maybe operatively connected to the first differential shaft 34-1, while thesecond parallel-shaft transfer gear-set 132-2 may be operativelyconnected to the second differential shaft 34-2.

As shown in FIG. 2, each of the first and second differential shafts34-1, 34-2 includes respective splined ends or attached gears 38A-1,38A-2. Each of the first and second parallel-shaft transfer gear-sets132-1, 132-2 includes respective first and second intermediate gears38B-1, 38B-2 arranged to rotate about a third axis Y3 that is parallelto each of the first and second axes Y1, Y2. The first and secondintermediate gears 38B-1, 38B-2 are continuously connected to gears38C-1, 38C-2. The first and second intermediate gears 38B-1, 38B-2transfer torque from the respective first and second differential shafts34-1, 34-2 to the first and second axle-shafts 28-1, 28-2 via respectiveaxle gear members 38D-1 and 38D-2.

FIG. 3 illustrates a final drive assembly 230, which is another specificembodiment of the final drive assembly 30 shown in FIG. 1. The finaldrive assembly 230 is similarly configured to transmit the drive torqueT2 to the first and second axle-shafts 28-1, 28-2. The final driveassembly 230 includes first and second gear-sets 232-1, 232-2 that, likethe respective first gear-sets 232-1, 232-2, are operatively connectedto the first and second axle-shafts 28-1, 28-2. Also similar to thepreviously discussed final drive assembly 130 of FIG. 2, in the finaldrive assembly 230, the motor-generator 22 arranged on the second axisY2 is configured to provide the drive torque T2 input to each of thefirst and second gear-sets 232-1, 232-2. As shown in FIG. 3, each of thefirst and second gear-sets 232-1, 232-2 in the final drive assembly 230having the differential gear-set 36 may be configured as a planetary orepicyclic gear-set. As shown, each of the first and second planetarygear-sets 232-1, 232-2 is configured to rotate about the first axis Y1and have first, second, and third members 42, 44, and 46, respectively.

The first planetary gear-set 232-1 is operatively connected to the firstdifferential shaft 34-1 and the second planetary gear-set 232-2 isoperatively connected to the second differential shaft 34-2.Specifically, the first differential shaft 34-1 is in mesh with thethird member 46 of the first planetary gear-set 232-1 via a thirdparallel-shaft transfer gear-set 232-3, and the second differentialshaft 34-2 is in mesh with the third member 46 of the second planetarygear-set 232-2 via a fourth parallel-shaft transfer gear-set 232-4.Additionally, the first axle-shaft 28-1 is continuously connected, i.e.,for simultaneous rotation without interruption of the connection or theresultant transmission of torque, to the second member 44 of the firstplanetary gear-set 232-1, while the second axle-shaft 28-2 iscontinuously connected to the second member 44 of the second planetarygear-set 232-2. In each of the first and second gear-sets 232-1, 232-2,the first member 42 may be a ring gear, the second member 44 may be aplanetary carrier supporting a plurality of pinion gears 58 in mesh withthe first and second members, and the third member 46 may be a sun gear,as understood by those skilled in the art.

According to a separate embodiment shown in FIG. 4, a final driveassembly 330 is disclosed that is similar to the final drive assemblyembodiments 130 and 230 in being configured to transmit the drive torqueT2 to the first and second axle-shafts 28-1, 28-2. The final driveassembly 330 includes first and second gear-sets 332-1, 332-2 that,similarly to the respective first gear-sets 332-1, 332-2, areoperatively connected to the first and second axle-shafts 28-1, 28-2.Also analogous to the previously discussed embodiments of FIGS. 2 and 3,the motor-generator 22 arranged on the second axis Y2 is configured toprovide the drive torque T2 input to each of the first and secondgear-sets 332-1, 332-2. The final drive assembly 330 is characterized byan absence of a separate and distinct differential gear-set 36, such asused by the embodiments of FIGS. 2 and 3. The embodiment of FIG. 4utilizes differential rotation of a member of each of the first andsecond gear-sets 332-1, 332-2 to allow the first and second axle-shafts28-1, 28-2 to rotate at different speeds, while each of the first andsecond gear-sets receives the drive torque T2.

Each embodiment of the contemplated embodiments of the final driveassembly 30, i.e., final drive assemblies 130, 230, and 330, maygenerally include a final drive case or housing 39 configured to enclosevarious components disclosed and described herein. In the final driveassembly 330 shown in FIG. 4 the stator 22-1 of the motor-generator 22is fixed to the final drive housing 39. The motor-generator 22 alsoincludes an outer shaft 40 fixed to the rotor 22-2 for rotationtherewith. In the final drive assembly 330, similar to the final driveassembly 230 embodiment shown in FIG. 3, each of the first and secondgear-sets 332-1, 332-2 is configured as a planetary gear-set, configuredto rotate about the first axis Y1. Similar to the embodiment illustratedin FIG. 3, each of the first and second gear-sets 332-1, 332-2 havefirst, second, and third members 42, 44, and 46, respectively. The outershaft 40 is in mesh with each of the third member 46 of the firstplanetary gear-set 332-1 and the third member of the second planetarygear-set 332-2.

As shown in FIG. 4, the final drive assembly 330 also includes an innershaft 48 extending through the outer shaft 40. The inner shaft 48 is inmesh with the first member 42 of the first planetary gear-set 332-1, andis also operatively connected to the first member 332-1 of the secondplanetary gear-set 332-2. Specifically, the inner shaft 48 may beoperatively connected to the first member 42 of the second planetarygear-set 332-2 via an idler gear 50 configured to reverse direction ofrotation 52 of the first member of the second planetary gear-setrelative to a direction of rotation 54 of the inner shaft 48.

When the inner shaft 48 and the idler gear 50 are so connected andconfigured, and the first member 42 of the first planetary gear-set332-1 is rotating, the second planetary gear-set 332-2 rotates in theopposite direction. Rotation of the first member 42 of each of theplanetary gear-sets 332-1, 332-2 changes the speed of rotation of theaxle shafts 28-1, 28-2, and allows them to rotate at different speeds.The final drive assembly 330 may include an actuator 56 configured toselectively modify the operation of the inner shaft 48 and idler gear50. In the embodiment shown, the actuator 56 is configured to disconnectthe inner shaft 48 from one of the first and second planetary gear-sets332-1, 332-2. Specifically, as shown in FIG. 4, the actuator 56 may bearranged in operative connection with the idler gear 50 and include asolenoid 56A configured to shift the idler gear into meshed engagementwith each of the first member 42 and the inner shaft 48. Alternatively,the actuator 56 may be arranged in operative connection with the idlergear 50 to act as a clutch configured to impede or prevent rotation ofthe idler gear.

As shown in FIG. 4, the first axle-shaft 28-1 is continuously connectedto the second member 44 of the first planetary gear-set 332-1.Similarly, the second axle-shaft 28-2 is continuously connected to thesecond member 44 of the second planetary gear-set 332-2. Similar to theembodiment of FIG. 3, in each of the first and second gear-sets 332-1,332-2, the first member 42 may be a ring gear, the second member 44 maybe a planetary carrier supporting a plurality of pinion gears 58 in meshwith the first and second members, and the third member 46 may be a sungear, as understood by those skilled in the art.

As shown in FIG. 1, the vehicle 10 also includes a programmablecontroller 60 configured to achieve desired propulsion of the vehicle 10in response to command(s) from an operator of the subject vehicle.Specifically, the controller 60 may be programmed to regulate andcoordinate operation of the first power-source, such as the internalcombustion engine 12, and the final drive assembly 30. Accordingly, thecontroller 60 may control the operation of the motor-generator 22, aswell as the actuator 56, to appropriately transmit drive torque T2 tothe first and second axle-shafts 28-1, 28-2. To accomplish the above,the controller 64 may include a processor and tangible, non-transitorymemory, which includes instructions for operation of the final driveassembly 30 programmed therein. The memory may be any recordable mediumthat participates in providing computer-readable data or processinstructions. Such a recordable medium may take many forms, includingbut not limited to non-volatile media and volatile media.

Non-volatile media for the controller 60 may include, for example,optical or magnetic disks and other persistent memory. Volatile mediamay include, for example, dynamic random access memory (DRAM), which mayconstitute a main memory. Such instructions may be transmitted by one ormore transmission medium, including coaxial cables, copper wire andfiber optics, including the wires that comprise a system bus coupled toa processor of a computer. Memory of the controller 60 may also includea floppy disk, a flexible disk, hard disk, magnetic tape, any othermagnetic medium, a CD-ROM, DVD, any other optical medium, etc. Thecontroller 60 may be configured or equipped with other required computerhardware, such as a high-speed clock, requisite Analog-to-Digital (A/D)and/or Digital-to-Analog (D/A) circuitry, any necessary input/outputcircuitry and devices (I/O), as well as appropriate signal conditioningand/or buffer circuitry. Any algorithms required by the controller 60 oraccessible thereby may be stored in the memory and automaticallyexecuted to provide the required functionality of the final driveassembly 30.

The detailed description and the drawings or figures are supportive anddescriptive of the disclosure, but the scope of the disclosure isdefined solely by the claims. While some of the best modes and otherembodiments for carrying out the claimed disclosure have been describedin detail, various alternative designs and embodiments exist forpracticing the disclosure defined in the appended claims. Furthermore,the embodiments shown in the drawings or the characteristics of variousembodiments mentioned in the present description are not necessarily tobe understood as embodiments independent of each other. Rather, it ispossible that each of the characteristics described in one of theexamples of an embodiment may be combined with one or a plurality ofother desired characteristics from other embodiments, resulting in otherembodiments not described in words or by reference to the drawings.Accordingly, such other embodiments fall within the framework of thescope of the appended claims.

What is claimed is:
 1. A final drive assembly for a vehicle drive axlehaving first and second axle-shafts that are configured to rotate abouta common first axis, the final drive assembly comprising: a firstgear-set configured to be operatively connected to the first axle-shaft;a second gear-set configured to be operatively connected to the secondaxle-shaft; an electric motor configured to provide an electric motortorque input to each of the first and second gear-sets and arranged on asecond axis that is parallel to the first axis; a first differentialshaft operatively connected to the first gear-set and a seconddifferential shaft operatively connected to the second gear-set; adifferential third gear-set operatively connecting the electric motor tothe first and second differential shafts; and first and second axle gearmembers arranged to rotate about the first axis and operativelyconnected to the respective first and second axle-shafts; wherein: thefirst and second gear-sets are configured as first and secondparallel-shaft transfer gear-sets, respectively; the firstparallel-shaft transfer gear-set is operatively connected to the firstdifferential shaft and the second parallel-shaft transfer gear-set isoperatively connected to the second differential shaft; each of thefirst and second parallel-shaft transfer gear-sets includes respectivefirst and second intermediate gears arranged to rotate about a thirdaxis that is parallel to each of the first and second axes; and thefirst and second intermediate gears transfer torque from the respectivefirst and second differential shafts to the respective first and secondaxle-shafts via the respective axle gear members.
 2. The final driveassembly according to claim 1, further comprising a final drive housing,wherein the electric motor includes a stator fixed to the final drivehousing and a rotor configured to transfer the electric motor torqueinput to the differential third gear-set.
 3. The final drive assemblyaccording to claim 1, wherein: each of the first and second differentialshafts includes one of a respective splined end and an attached gear;and each of the one of the respective splined end and the attached gearis configured to transfer torque from the respective first and seconddifferential shafts to the respective first and second axle-shafts.
 4. Avehicle drive axle comprising: a first road wheel and a second roadwheel; a first axle-shaft operatively connected to the first road wheeland a second axle-shaft operatively connected to the second road wheel,wherein each of the first and second axle-shafts is configured to rotateabout a common first axis; and a final drive assembly configured totransmit a drive torque to the first and second axle-shafts, the finaldrive assembly including: a first gear-set operatively connected to thefirst axle-shaft; a second gear-set operatively connected to the secondaxle-shaft; an electric motor configured to provide the drive torqueinput to each of the first and second gear-sets and arranged on a secondaxis that is parallel to the first axis; a first differential shaftoperatively connected to the first gear-set and a second differentialshaft operatively connected to the second gear-set; a differential thirdgear-set operatively connecting the electric motor to the first andsecond differential shafts; and first and second axle gear membersarranged to rotate about the first axis and operatively connected to therespective first and second axle-shafts; wherein: the first and secondgear-sets are configured as first and second parallel-shaft transfergear-sets, respectively; the first parallel-shaft transfer gear-set isoperatively connected to the first differential shaft and the secondparallel-shaft transfer gear-set is operatively connected to the seconddifferential shaft; each of the first and second parallel-shaft transfergear-sets includes respective first and second intermediate gearsarranged to rotate about a third axis that is parallel to each of thefirst and second axes; and the first and second intermediate gearstransfer torque from the respective first and second differential shaftsto the respective first and second axle-shafts via the respective axlegear members.
 5. The vehicle drive axle according to claim 4, whereinthe final drive assembly additionally includes a final drive housing,and wherein the electric motor includes a stator fixed to the finaldrive housing and a rotor configured to transfer the electric motortorque input to the differential third gear-set.
 6. The vehicle driveaxle according to claim 4, wherein: each of the first and seconddifferential shafts includes one of a respective splined end and anattached gear; and each of the one of the respective splined end and theattached gear is configured to transfer torque from the respective firstand second differential shafts to the respective first and secondaxle-shafts.